Modular buildings

ABSTRACT

A building module has an open-ended box structure and comprises a plurality of interconnected coaxial module segments. Each segment is moulded as an open-ended box structure from a composite material. The segments are held together by elongate tie bars that form part of a lifting frame and extend substantially along the length of the module. The lifting frame comprises end frames that are embedded in end segments of the modules and that are connected to each other by the tie bars. The modules structure

The present invention relates to modular buildings.

It is well known to provide for modular building structures in which aplurality of prefabricated, portable, modular units are assembled into acomplete building construction. Such structures are typically used incircumstances where accommodation is needed in an emergency or on atemporary basis and this has to be rapidly and easily assembled to meetthe demand for emergency habitable structures in times, for example, ofnatural or other disasters. In addition, such buildings are oftenrequired in remote locations by workers employed in the constructionindustry where temporary accommodation is needed during the term of theconstruction project.

There is a need for an all-purpose modular building system that can beexploited by both the residential and commercial construction sectors ofindustry. To date, portable and prefabricated building designs have notproved suitable for application in both sectors. Modular buildings havethe advantages that they are easy and quick to erect, dismantle orrelocate, are readily transportable, and flexible in that they arere-configurable to meet changing size or other requirements.Unfortunately existing designs of such buildings are generally of atemporary nature and are not suited to long-term or permanentapplications.

Existing modular buildings suffer from several disadvantages including:racking which causes wear and tear to the structure of the building andoften leads to leaks, creaks and structural damage; condensation;inadequate interior temperature control; ineffective noise insulation;and an excessive ingress of dirt and dust (particularly in environmentssuch as construction sites).

A modular building structure that obviates or mitigates the aforesaiddisadvantages is described in my PCT patent application No. WO 00/01898.The modular building structures described therein comprise a corridorwalkway module to which are connected separate accommodation modulesthat form offices or accommodation etc. The floor or ceiling of thecorridor walkway carries mains services to the accommodation modules.The structures have improved life expectancies whilst retaining thebenefits of modular construction.

The object of the present invention is to provide for a modular buildingstructure that is an improvement over the designs described in myaforementioned PCT application.

According to a first aspect of the present invention there is provided abuilding module having an open-ended box structure with top, bottom andopposed side walls and comprising a plurality of interconnected coaxialmodule segments each being moulded as an open-ended box structure from acomposite material, at least one of the segments having a strengtheningbeam spanning the opposed side walls.

The segmented structure of the building module of the present inventionprovides for a very flexible arrangement in which the length of a modulecan be varied by selection of the appropriate number of segments. Bymoulding the composite material of one or more segments around a liftingframe the module is compact but easily transportable. The open-ended boxstructure provides for a very rigid construction without the need forexpensive superstructures or foundations and with resistance to racking.Moulds may be produced of different widths.

The beam provides extra strength to counteract racking or other similarmovement and provides a neat and compact formation on which a floor orceiling structure can be mounted. It is preferably connected to one orother of the top and bottom walls.

The strengthening beam may be connected to the bottom wall and maysupport a floor structure or may be, additionally or alternatively,connected to the top wall and may support a ceiling structure. The beamor beams may be integrally moulded with the segment.

The beam of each segment preferably has ports to allow passage ofservice conduits below the module floor or above the module ceiling.Service conduits such as water or waste pipes and electrical cables canthus be disposed easily below floor or above ceiling level beforepassing through the floor or ceiling to feed appliances in the module.

At least one of the segments may have an integral lifting frame by whichthe module may be lifted for transportation or assembly into a buildingstructure.

In a preferred embodiment at least two of the segments have a liftingframe and the frames are interconnected by a plurality of elongatesupport members.

The elongate support members may be connected to the segments via partof the lifting frame.

At least some of said elongate support members may be disposed above aceiling of the module and at least some of said elongate support membersmay be disposed, additionally or alternatively, below a floor of themodule. In each case the members preferably pass through apertures inthe corner of the segment and ideally through apertures in the beams.

In a preferred embodiment the end segments of the module have integralframes and a mid-module segment also has an integral frame.

The frame may comprise a pair of spaced substantially vertical postsinterconnected by upper and lower cross-members. The posts may beconnected to the cross-members by means of corner plate members.

Preferably the corner plate members comprise first and second connectorportions disposed substantially at a right angle to each other.Furthermore, the first and second connector portions may be joined by anintermediate arcuate portion in which part of the post is received.

The corner plate may be connected to the elongate support member.

Ideally the posts have adjustable feet for altering the height of themodule relative to the ground.

An upper end of the post may be fitted with a lifting attachment bywhich the module may be lifted. Alternatively an upper end of the postis fitted with an inter-module connector for interconnecting verticallyadjacent modules.

The exterior of the side and end walls of the module may have at leastone channel in which is received a resiliently flexible material.

The composite material is preferably a water extendable polyester resinwith a mineral filler.

At least one of the segments may have an upper wall in which there isdisposed reinforcing mesh material.

The segments may be connected to one another by a tongue and grooveformation. Although alternative joints may be used.

The module has a side wall in which there may be ports that allowpassage of service conduits. Such ports allow the service conduits topass laterally of the module to adjacent modules or elsewhere,preferably above ceiling level or below floor level. The segments arepreferably of a unitary construction but may be formed of one or moreconnected parts.

According to a second aspect of the present invention there is provideda building structure comprising a plurality of building modules asdefined above.

According to a third aspect of the present invention there is provided abuilding structure comprising a plurality of interconnected open-endedbox structure building modules, wherein there is provided a resilientlydeformable material sandwiched between adjacent walls of at least twomodules.

A specific embodiment of the present invention will now be described, byway of example only, with reference to the accompanying drawings inwhich:

FIG. 1 is a schematic perspective view illustrating a typical modularbuilding structure embodying the present invention;

FIG. 2 is a schematic partially exploded perspective view illustratingthe interconnection of corridor and accommodation building modules ofthe present invention;

FIG. 3 is a schematic perspective view of a building module of thepresent invention shown in a slightly exploded configuration;

FIG. 4 is a sectioned side elevation of the building module of FIG. 3shown with an end wall spaced from the rest of the module;

FIG. 5 is a sectioned plan view of the module of FIG. 4;

FIG. 6 is a cross-section through a mid-point of the module of FIGS. 3and 4;

FIG. 7 is a perspective view of the front of an intermediate segment ofthe module of FIGS. 3 to 5;

FIG. 8 is a rear perspective view of the intermediate segment of FIG. 7;

FIG. 9 is a front perspective view of a front end fascia segment of themodule of FIGS. 3 to 5;

FIG. 10 is a rear perspective view of the front end fascia segment ofFIG. 9;

FIG. 11 is a front perspective view of a lifting frame of the buildingmodule of the present invention;

FIG. 12 is a sectioned schematic side elevation of the building moduleof FIGS. 3 to 5 shown fitted with the lifting frame of FIG. 11;

FIG. 13 is a sectioned plan view of the module of FIG. 12;

FIG. 14 is an end view of the module of FIG. 13;

FIG. 15 is a perspective isometric view of a post of the lifting frameof FIG. 11;

FIGS. 16 a and 16 b are part-sectioned views of an upper portion of thepost of FIG. 15 showing interchangeable connectors;

FIGS. 17 a and 17 b show part-sectioned views of a lower portion of thepost of FIG. 15 showing an interchangeable leg and connector;

FIG. 18 is a cross-sectioned plan view of a corner of the buildingmodule of FIG. 12, taken below floor level;

FIG. 19 is a cross-sectioned front elevation of the corner shown in FIG.18;

FIG. 20 is a cross-sectioned plan view of a corner of the buildingmodule of FIG. 12, taken at ceiling level;

FIG. 21 is a cross-sectioned front elevation of the corner shown in FIG.20;

FIGS. 22 and 23 are, respectively, side and end views of the buildingmodule of FIG. 3 to 5 and 12, showing filleting channels;

FIG. 24 is a plan view of the module of FIGS. 22 and 23 and shows topsof the lifting frames;

FIGS. 25 a and 25 b are sectioned side views of part of two modules ofthe present invention and illustrate the interconnection betweenadjacent modules;

FIG. 26 is a sectioned end view of a half fillet used in theinterconnection of building modules of the present invention;

FIG. 27 is a sectioned end view of a fillet pad used in theinterconnection of vertically stacked building modules of the presentinvention;

FIG. 28 is a perspective view of a stairwell building module;

FIG. 29 is a plan view of an alternative building structure; and

FIG. 30 is a plan view of a further alternative building structure.

Referring now to the drawings, an exemplary embodiment of a modularbuilding structure of the present invention is illustrated in FIG. 1.The structure is in the form of a motorway hotel or motel and comprisesa plurality of prefabricated, pre-fitted, self-supporting buildingmodules arranged in both vertical and horizontal array. The buildingmodules are divided into a plurality of corridors 10 to each of whichare connected a plurality of accommodation modules 11 that form thehotel rooms. The corridors 10 form passageways that, in addition toproviding walkways between accommodation modules 11, carry anddistribute service supply lines to the accommodation modules 11. Thebuilding shown has multiple storeys that are interconnected bystairwells 11 a.

FIG. 2 shows part of the structure of FIG. 1 and illustratesschematically the connection of a two-storey group of accommodationmodules 11 to a pair of corridor modules 10 that are disposed invertical array. Each accommodation and corridor module is of the samebasic construction as will be described below and is in the form of anopen-ended box configuration with an internally mounted floor 12 andceiling 13. The interconnection of the accommodation modules 11 toadjacent accommodation modules 11 and to the adjacent corridor module 10will be described in detail below. Door openings 14 are provided atspaced intervals on each side wall of the corridor 10 so as to provideaccess to the adjoined accommodation module 11.

The building modules 10, 11 are each constructed from a plurality ofcoaxial segments 15 of open-ended box shape as shown in schematicarrangement in FIG. 3 (the segments are shown slightly separated fromone another for clarity). Each segment is in the form of a unitaryrectangular frame moulded from a composite material such aswater-extended polyester resin with water and a mineral filler that isdescribed in UK patent no. 2306495B. This is a particularly suitablematerial as it is a natural insulator against heat and has elasticcharacteristics that allow the module to bend slightly and render itshock absorbent. However, other composite materials such as concrete,cement, ceramic or any appropriate syntactic composite material may beused. The segment frame may be divided into separate interconnectedmoulded parts if appropriate. The connection of segments to each otheris described below.

In the exemplary embodiment shown in FIGS. 4 to 6, each module comprisesa front end fascia segment 16, a rear-end fascia segment 17, amid-support segment 18 and a plurality of intermediate segments 19. Theprecise arrangement may vary depending on the intended use of themodule. For example, the number of intermediate segments 19 may beincreased or decreased depending on the length of module required and inshorter modules the mid-support segment 18 may be omitted. The segments16 to 19 are engaged with one another by means of a tongue and grooveconnection 20 and are bonded to each other by a suitable adhesive.

Each intermediate segment 19 (shown in detail in FIGS. 7 and 8)comprises upper 21, lower 22 and side walls 23. The upper 21 and lowerwalls 22 are relatively thin in comparison to the thickness of the sidewalls 23 and may include reinforcement in the form of a wire mesh (notshown) embedded in the moulded material. At the front end of eachsegment 19 there are beams 24 integrally connected to the upper 21 andlower walls 22. As well as imparting additional rigidity to the modulesegments, the beams 24 provide support for the floor 12 and ceiling 13and each comprise a vertical section 25 and a terminal horizontalsection 26 disposed parallel to the upper 21 and lower walls 22. Each ofthe side walls 23 has ports 27 at its upper and lower ends for receivingservice conduits (not shown). The vertical portions 25 of the beams 24have a central port 28 and two flanking ports at 29 for the same reason.Smaller apertures 30 are provided near the comer of the beam 24 forreceipt of a tie bar as will be described below.

The remaining segments are of the same general construction as theintermediate segments. Features that differ from the intermediatesegments will be described below.

The front end fascia segment 16 (FIGS. 9 and 10) differs from theintermediate segment 19 in that the floor and ceiling support beams 31extend in the vertical direction only. The beams 31 are integrallyconnected to the lower and upper walls 22, 21 respectively and each hasa large central port 32 flanked by two smaller ports 33 (intended forintermodule fastenings as described below) and two small tie-barapertures 30 as before. The side walls 23 have two small ports 34, oneadjacent to each of the upper and lower walls 21, 22.

The rear end fascia segment 17 (FIGS. 5 and 6) has first upper and lowervertical beams 35 at its rear end that are identical in configuration tothat of the front end fascia (including the port configuration) andupper and lower second beams 36 at its rear end that are identical tothe corresponding beams 24 on an intermediate segment 19. The segment 17is fitted with an end wall frame 37 (shown in FIGS. 4 and 5) thatpartially closes the opening at the rear end of the segment and is fixedto an inwardly facing edge 38 of the first vertical beams 35. The beams35 for the rear end fascia may be moulded separately and bonded to thewalls of the segment.

The mid-support segment 18 is of substantially the same configuration asthe front end fascia segment 16 and has only a vertical beam 39 thatcorresponds to those on the front and rear end fascia segments 16, 17.

The side walls of each of the segments may have internal verticalconduits formed during the moulding process. These are used, typically,to receive electrical cables. The conduits extend from below the floorto above the ceiling.

Moreover, suitable blanks in the modules may be used to form openings inthe side walls for doors or windows.

The segments 15 of each building module are held together by fourparallel longitudinally extending tie bars 40 that pass through theaforementioned corner apertures 30 of each segment 16-19 as shown inFIGS. 4 and 5. The tie bars 40 form part of a box-shaped lifting frame41 (shown in detail, separate from the building module, in FIG. 11) andare secured at each end to an end frame 42 of the lifting frame 41 bymeans of a threaded nut 43 in such a way that the segments are clampedtogether. Each end frame 42 is embedded in the front and rear end fasciasegments 16, 17 in the moulding process and comprises two vertical posts44 that are spaced apart horizontally by the approximate width of themodule. The posts 44 are received in sleeves 45 at their lower ends andare connected to each other by upper and lower horizontal bars 46, 47that are connected at each end to corner members 48 of the end frame 42.Each comer member 48 comprises a substantially right-angled plate havingperpendicular first and second connector portions 49, 50 joinedintegrally by an arcuate portion 51 that receives the post 44 or thesleeve 45. The first connector portion 49 of the corner member 48extends in parallel to the horizontal bars 46, 47 and is connectedthereto by four bolts 52. The second connector portion 50 extends in adirection parallel to the longitudinal axis of the tie bars 40 and has asingle aperture 53 (shown in FIG. 12) for register with the port 34 inthe side wall 23 of the end fascia segments 16 or 17. Each horizontalbar 46 has a central port 54 that is flanked by two smaller ports 55that also pass through the first connector portion 49 of the cornermember 48.

The front and rear end segments 16, 17 are moulded around the end frame42 components of the lifting frame as shown in FIGS. 12, 13 and 14. Inapplications where the module is of such a length that a mid-supportsegment 18 is required, a further mid-frame 56 of identicalconfiguration to the end frames 42 is provided as shown.

Each of the posts 44 of the end frames 42 have vertically spaced spigots57 for connection to lifting tackle (not shown in the drawings). Thepost may also be fitted at vertically spaced intervals with a claddingsupport member that projects to the outer surface of the moulded segmentand has exposed sockets for the receipt of fixings that secure claddingto the module surface.

Referring now to FIGS. 15 and 17 a, the sleeve 45 comprises a threadedcollar 58 in which a threaded end 59 of the post 44 is received and afurther portion in the form of a cylindrical housing 60. The collar 58and the housing 60 are disposed in a vertically spaced relationship inthe arcuate portion 51 of the corner member 48 that interconnects theperpendicular connecting portions 49, 50. The housing 60 receives asupport leg 61 having a disc-shaped foot 62 and a threaded upstandingstem 63 that is received in an internally threaded leg holder 64disposed in the space between the collar 58 and housing 60. The leg 61extends from the bottom of the module and is adjustable in height byvirtue of the threaded connection with the leg holder 64.

The upper end of each post 44 is closed by a cap 65 that has a centralthreaded aperture 66 for receiving fastenings as shown in FIGS. 16 a and16 b. The fastening shown in FIG. 16 a is an eye bolt 67 that isthreadedly engaged in the cap aperture 66 and provides an eye to whichlifting tackle may be connected. The eye bolt 67 may be replaced by aninter-module connector 68 such as the half grommet fastening shown inFIG. 16 b. Such connectors were described in my aforementioned patentapplication and are used to connect the module to a vertically adjacentmodule.

At the lower end of the posts 44 the support legs 61 may be replaced bya half grommet fastening 69 has shown in FIG. 17 b. The threaded end 70of the fastening 69 extends from the housing 60 and is used to connectthe base of the module to appropriate foundation members (not shown).

FIGS. 18 and 19 show, in section, a corner of the front or rear endfascia segment 16, 17 below floor level. The shaded region indicates acut away area 71 that provides access to the half grommet fastening 69or the support leg 61. In FIG. 19 there is also shown, in dotted line,below the cut-away area 71, a housing 72 for inter-module connectorsthat are described later. The lower horizontal bar 47 and tie-bar 40shown are connected to the first connector portion 49 of the comermember 48 by a slightly different arrangement of bolts as compared tothat shown in FIG. 11.

FIGS. 20 and 21 show the end frame 42 connections at ceiling level.Again the inter-module connection housing 72 is shown in dotted line inFIG. 20 and, again, the connection of the upper horizontal bar 46 andthe tie-bar 40 to the second connector portion 49 of the corner member48 is of slightly different configuration to that shown in FIG. 11.

The dotted lines 73 in FIGS. 18 and 20 indicate an elongate channel inand along the edge of the upper and lower walls 21, 22. This channel 73is shown more clearly in the context of the overall module structure inFIGS. 22 and 23. It extends along all four edges of the side walls 23and edges of the front and rear end segments as shown and is designed toreceive an elongate fillet strip 74 (shown in FIGS. 25 a and 25 b) madeof a flexible resilient material, typically EPDM. The strip 74 hasprofiled faces that are complementary to the profile of the channel andthe walls on either side of the channel 73. It is bonded in the channeland allows limited relative movement of adjacent modules. Its resilientqualities allows for minor misalignment of adjoining modules both duringinitial construction and subsequently as a result of settling,subsidence, thermal expansion and contraction as well as the absorptionof shock from earth tremors or the like. The strip 74 acts as a heat andsound insulator so as to limit the transference of noise, vibration andheat (such as that created by a fire) between modules. Finally, thestrip 74 also acts as a seal so as to prevent surface water penetratinginto the small clearance between the modules.

The top ends of the posts 44 of the lifting frame 41 are exposed to theexterior surface of the upper wall 21 of the module as shown in FIG. 24.

The interconnection of adjacent modules 10, 11 is illustrated in FIGS.25 a and 25 b. The fixing between the modules is a grommet fastening 75of the kind described in my aforementioned patent application. Aflexible grommet 76 is received in grommet housings 72 of the side walls23 of adjacent modules and the walls are secured together by collars 76that are received in recesses 77 around the openings to the housings 72.The collars 76 (two different types are shown in the figures) aremounted on the end of respective threaded bolts 78 which, in turn, arethreadedly engaged in opposed axial apertures 79 in the grommet 76. Thebolts 78 allow the interconnection of the modules to be tightened. Thefillet strip 74 is received in the channels 73 of adjacent modules andis sandwiched between the modules.

Where an end face of a module is connected to the side wall 23 ofanother (e.g. a corridor) the grommet housings are received in parts 33of the beams 31 of the end fascia and two half fillet strips 80 (shownin FIG. 26) are used. The half fillet strip 80 has a flat side 80 a anda profiled side 80 b corresponding to the profile of the full filletstrip 80 referred to above. The flat sides 80 a of two half filletstrips 80 are bonded side wall 23 of one module at positions that willmate with the end wall channel 73 of the other module. The full filletstrips 74 are then placed in the top and bottom channels 73 of either ofthe modules such that when the two modules are offered into position thefillets 74 provide a seal. The modules are then secured together withupper and lower grommet fastenings 75.

Vertically stacked modules are separated by a fillet pad 81 (shown inFIG. 27) that is bonded to the underside edges of the upper module andprovides the same function as the other fillet strips 74, 80.

The same basic structure of an accommodation module can be used to forma stairwell 90 as is shown in FIG. 28. Three vertically stacked modulesfrom the stairwell and the interfacing (upper and/or lower) walls of themodules are removed so as to accommodate the internal stair structure91.

FIG. 29 shows one embodiment of the layout of a hotel having a structurein accordance with the present invention. The hotel has a main areacomprising separate interconnected modules that are respectivelyinternally fitted to form an office 101, a staircase 102, reception 103,a lounge 104 and a service module 105. The lounge 104 is connected to acorridor module 106 to which are attached a plurality of flankingaccommodation modules 107.

The service module 105 contains a water boiler 110 for the supply of hotwater to each of the accommodation modules 107 via water conduits 111,and electrical switchgear 112. The water conduits 111 pass along thecorridor module 106 (under the floor or above the ceiling) and feed intoa bathroom unit 113 in each accommodation module 107. The boiler 110also feeds a central heating system and the associated conduits 114 passfrom the boiler 110 laterally out of the side wall ports 27 in theservice module 105 and into the adjacent accommodation module 108through side wall ports 27 under the floor 12. The conduits 114 connectto a radiator 115 in that module and pass through the side wall ports27, 34 and/or the ports 28, 29, 31, 32, 33 in the beams to radiators 115in each of the successive modules as shown, before returning to theboiler 110.

Each module is similarly attached to an external waste disposal system120 with waste conduits 121 passing laterally under the module floor 12from the bathroom fixtures of each module to connect with the main wastedisposal system outside the module.

It will be appreciated that the segmented configuration of the modulesallows modules of differing sizes to be constructed. In FIG. 30 there isshown an alternative layout for a motorway hotel or motel. The groundfloor and first floor are shown separately and comprise a centralstructure 200 that is flanked on each side by accommodation modules 201.A corridor 202 provides communication between the central structure 200and the accommodation modules 201 on each side. This building structureconfiguration is constructed from six different module arrangements asis shown by the key. There are sixty four modules of the type designated1 and these are identical to each other save for different interiorfittings and different end walls. There are two modules of the typedesignated 2 that are part of a ground floor reception area 205 and alaundry/store room 206 directly above; two modules of the typedesignated 3 that complete the central structure 200; two stairwaymodules designated 4; and sixteen corridor modules, eight of the typedesignated 5 and eight of the type designated 6.

It is to be appreciated that whilst the aspects of the present inventionhave been described with reference to exemplary embodiments taking theform of hotel modules, they may apply to other building structures suchas, for example, offices, leisure, retail or industrial complexes orother forms of accommodation.

The general open-ended box structure with strengthening beams providesfor a very versatile and robust building module.

The open-end box configuration provides the versatility in that it canbe connected to another module in many different ways (e.g. end-to-endor end-to-side) and can receive any suitable end wall for the particularapplication.

The strengthening beams provide rigidity against racking or otherdeformation of the box structure and may conveniently be used to supporta floor and/or ceiling structure.

The segmented configuration of the structure provides for versatility inthat a module may be constructed of any desired length. Moreover, such aconfiguration permits easy manufacture by moulding.

The segments may be produced in a range of different sizes to suitdifferent applications. In addition to differences in depth, therelative lengths, and thickness of the walls or the width of thesegments may be varied.

The provision of ports in the side walls and beams at regular intervalsenhances the modular and flexible nature of the product. The side wallports allow services to be provided from any direction. This is incontrast to the arrangement described in my aforementioned patentapplication in which services were provided along a corridor for supplythrough an end face of each building module. The present arrangementeliminates the need for a supply corridor module.

It is also to be appreciated that numerous embodiments may be made tothe described embodiments without departing from the scope of thepresent invention as defined in the appended claims. For example, theend frame section of the lifting frame may be provided only one segmentwhere the module is short in length, although end frames are preferablyprovided at least on each end segment. In an alternative embodiment thelifting frame may be eliminated entirely.

1. A building module having a box structure with top, bottom and opposed side walls, and an open interior, said building module comprising a plurality of interconnected coaxial discrete module segments which individually comprise an open-ended box structure molded from a composite material, each segment having top, bottom and opposed side walls that combine to define a box with an open interior and opposed open ends, the segments being disposed in an end-to-end relationship such that the side walls of the segments combine to form the side wall of the module, the bottom walls of the segments combine to form the bottom wall of the module, and the open interiors combine to define the open interior of the module, at least one of the segments having a strengthening beam spanning its opposed side walls. 2-34. (canceled) 